Three-dimensional printing along a curved surface

ABSTRACT

A method and apparatus for printing onto a curved surface of an article are disclosed. An embodiment of a method may include receiving the article and extruding a composite yarn from a nozzle. A method may include attaching the composite yarn to the curved surface by moving the nozzle in a direction aligned with a first axis and a direction aligned with second axis along the curved surface. The first axis may be approximately normal to the print surface and the second axis may be approximately normal to the first direction. The article may be repositioned during printing to accommodate nozzle movement.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.14/935,977, filed on Nov. 9, 2015, which is incorporated by referenceherein.

BACKGROUND

The present embodiments relate generally to three-dimensional printingsystems and methods.

Three-dimensional printing systems and methods may be associated withvarious technologies including fused deposition modeling (FDM), electronbeam freeform fabrication (EBF), and selective laser sintering (SLS), aswell as other kinds of three-dimensional printing technologies.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic view of an embodiment of components of athree-dimensional printing system as well as several articles that maybe used with the three-dimensional printing system;

FIG. 2 is a schematic view of an embodiment of a printing device and abase;

FIG. 3 is a schematic view of an embodiment of an article and a printingdevice;

FIG. 4 is a schematic view of an embodiment of an article and a printingdevice;

FIG. 5 is a schematic view of an embodiment of an article and a printingdevice;

FIG. 6 is a schematic view of an embodiment of an article and a printingdevice;

FIG. 7 is a schematic view of an embodiment of an article and a printingdevice;

FIG. 8 is a schematic view of an embodiment of an article and a printingdevice;

FIG. 9 is a magnified view of an embodiment of a portion of an articleand a printing device;

FIG. 10 is a magnified view of an embodiment of a portion of an articleand a printing device;

FIG. 11 is a magnified view of an embodiment of a portion of an articleand a printing device;

FIG. 12 is a schematic view of an embodiment of an article and a nozzleassembly;

FIG. 13 is a schematic view of an embodiment of an article and a nozzleassembly;

FIG. 14 is a schematic view of an embodiment of an article and a nozzleassembly;

FIG. 15 is a schematic view of an embodiment of an article and a nozzleassembly;

FIG. 16 is a schematic view of an embodiment of an article and a nozzleassembly;

FIG. 17 is a schematic view of an embodiment of an article and a nozzleassembly;

FIG. 18 is a schematic view of an embodiment of an article and a nozzleassembly; and

FIG. 19 is a schematic view of an embodiment of an article and a nozzleassembly.

DETAILED DESCRIPTION

In one embodiment, a method of printing on a curved surface may comprisepositioning an article in a first position on an upper surface of a baseof the printing system. The upper surface of the base defines a verticalaxis that is perpendicular to the upper surface of the base and theupper surface of the base defines a first horizontal axis that isparallel to the upper surface of the base and that is perpendicular tothe vertical axis. The method may further include discharging a printmaterial, such as a composite yarn, from a nozzle. The print surface mayinclude at least one curved area. By moving the nozzle in a directionaligned with the vertical axis over the print surface and simultaneouslymoving the nozzle in a direction aligned with the first horizontal axisover the print surface, the print material can be attached to a printsurface of the article using a print system. The nozzle is spaced at aprint distance from the print surface while attaching the print materialto the print surface.

In another embodiment, a method of printing a three-dimensionalstructure on a curved surface of an article may comprise placing thearticle on a base of a printing system, discharging a continuouscomposite yarn from a nozzle of the printing system, and attaching thecontinuous composite yarn to the curved surface of the article to form afirst portion of a first printed layer on the curved surface. The methodfurther comprises forming the first printed layer, the first printedlayer having an outer surface that is exposed, attaching the continuouscomposite yarn to at least a portion of the outer surface of the firstprinted layer and forming at least a second printed layer, and forming athree-dimensional first structure on the curved surface.

In another embodiment, an apparatus for printing onto a curved surfaceof an article may comprise a housing, where the housing includes a basedisposed along the bottom of the housing, and a nozzle configured todischarge a composite yarn onto the curved surface. The apparatus mayalso include a first actuating system configured to move the nozzle,where the first actuating system can move the nozzle along a directionaligned with a first vertical axis, the first vertical axis extendingnormal to a surface of the base, and where the first actuating systemcan move the nozzle along a direction aligned with a first horizontalaxis, the first horizontal axis being approximately parallel withrespect to the base. The apparatus is configured to attach the compositeyarn to the curved surface by moving the nozzle downward toward thecurved surface in a direction aligned with the first vertical axis, andthe apparatus is also configured to attach the composite yarn to thecurved surface by moving the nozzle in a direction aligned with thefirst horizontal axis.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

FIG. 1 is a schematic view of an embodiment of a three-dimensionalprinting system 100, also referred to simply as printing system 100hereafter. FIG. 1 also illustrates several exemplary articles 130 thatmay be used with printing system 100. Referring to FIG. 1, printingsystem 100 may further comprise a printing device 102, a computingsystem 104, and a network 106.

Embodiments may use various kinds of three-dimensional printing (oradditive manufacturing) techniques. Three-dimensional printing, or “3Dprinting,” comprises various technologies that are used to formthree-dimensional objects by depositing successive layers of material ontop of one another. Exemplary 3D printing technologies that could beused include, but are not limited to: fused filament fabrication (FFF),electron beam freeform fabrication (EBF), direct metal laser sintering(DMLS), electron beam melting (EMB), selective laser melting (SLM),selective heat sintering (SHS), selective laser sintering (SLS),plaster-based 3D printing (PP), laminated object manufacturing (LOM),stereolithography (SLA), and digital light processing (DLP), as well asvarious other kinds of 3D printing or additive manufacturingtechnologies known in the art.

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “longitudinal axis,” as used throughout thisdetailed description and in the claims, refers to an axis extending alength of a component. Thus, a “longitudinal direction,” as usedthroughout this detailed description and in the claims, refers to adirection aligned with a longitudinal axis.

The term “lateral axis,” as used throughout this detailed descriptionand in the claims, refers to a side-to-side axis extending a width of acomponent. For example, the lateral axis may extend between a medialside and a lateral side of an article of footwear, with the lateral sideof the article of footwear being the surface that faces away from theother foot, and the medial side being the surface that faces toward theother foot. Thus, a “lateral direction,” as used throughout thisdetailed description and in the claims, refers to a direction alignedwith a lateral axis.

The term “horizontal,” as used throughout this detailed description andin the claims, refers to any direction or axis that is substantiallyparallel with the longitudinal axis, the lateral axis, and alldirections in between. In cases where a component is placed on theground, a horizontal axis may be parallel with the ground.

The term “vertical,” as used throughout this detailed description and inthe claims, refers to an axis that is generally perpendicular to boththe lateral and longitudinal axes, along a substantially vertically(upward and downward) oriented axis. For example, in cases where acomponent is flat on a ground surface, the vertical axis may extend fromthe ground surface upward.

It will be understood that each of these directional adjectives may beapplied to individual components of a sole. Furthermore, the term “outersurface” as used throughout this detailed description and in the claims,refers to the surface of a component that is exposed or facing theexternal environment.

For purposes of this disclosure, the foregoing directional terms, whenused in reference to a printing system or an article of footwear orother article of apparel, shall refer to the articles when disposed on asubstantially flat surface. With respect to an article of footwear, thedirectional terms refer to the article when sitting in an uprightposition, with the sole facing groundward, that is, as it would bepositioned when worn by a wearer standing on a substantially levelsurface.

In the embodiments shown in the figures, printing system 100 may beassociated with fused filament fabrication (FFF), also referred to asfused deposition modeling. In the embodiment shown in FIG. 1, printingdevice 102 of printing system 100 may use fused filament fabrication toproduce three-dimensional parts. An example of a printing device usingfused filament fabrication (FFF) is disclosed in U.S. Pat. No. 5,121,329to Crump, issued Jun. 9, 1992, and titled “Apparatus and Method forCreating Three-Dimensional Objects,” which application is hereinincorporated by reference and referred to hereafter as the “3D Objectsapplication.” Embodiments of the present disclosure can make use of anyof the systems, components, devices, and methods disclosed in the 3DObjects application.

Printing device 102 may include a housing 110 that supports varioussystems, devices, components, or other provisions that facilitate thethree-dimensional printing of objects (e.g., parts, components, orstructures). Although the exemplary embodiment depicts a particularrectangular box-like geometry for housing 110, other embodiments coulduse any housing having any geometry and/or design. The shape and size ofhousing 110 could be varied according to factors including a desiredfootprint for the device, the size and shape of parts that may be formedwithin printing device 102, as well as possibly other factors. It willbe understood that housing 110 could be open (e.g., provide a frame withlarge openings) or closed (e.g., with glass or panels of solid materialand a door).

In some embodiments, printing device 102 may include provisions toretain or hold a printed object (or a component supporting the printedobject). In some embodiments, printing device 102 may include a table,base, platform, tray, or similar component to support, retain, and/orhold a printed object or an object onto which printed material isapplied. In the embodiment of FIG. 1, printing device 102 includes asurface that will be referred to as a base 112. In some embodiments,base 112 may be fixed in place and act as a stable base. In otherembodiments, however, base 112 could move. For example, in some cases,base 112 may be configured to translate within housing 110 in varioushorizontal directions (e.g., front-back and/or left right with respectto housing 110) as well as vertical directions (e.g., up-down withinhousing 110). Moreover, in some cases, base 112 may be configured torotate and/or tilt about one or more axes associated with base 112.Thus, it is contemplated that in at least some embodiments, base 112 maybe moved into any desired relative configuration with a nozzle or printhead of printing device 102. In other embodiments, printing device 102may not include a base 112. In some embodiments, base 112 may be curved,irregularly shaped, or shaped to provide a customized platform uponwhich an article or object may be placed or secured. However, in otherembodiments, base 112 may comprise a substantially flat surface. In someembodiments, printing device 102 may include an open space or cavityformed within base 112.

In some embodiments, printing device 102 may include one or moresystems, devices, assemblies, or components for delivering a printedmaterial (or printed substance) to a target location. Target locationscould include the surface of base 112, a surface or portion of apartially printed structure, and/or a surface or portion of anon-printed structure or component. Provisions for delivering printedmaterials may include, for example, print heads and nozzles. In theembodiment of FIG. 1, printing device 102 includes a nozzle assembly116.

Nozzle assembly 116 may comprise one or more nozzles that deliver aprinted material to a target location. For purposes of clarity, theexemplary embodiment of FIG. 1 depicts a single nozzle 118 of nozzleassembly 116. However, in other embodiments, nozzle assembly 116 couldbe configured with any number of nozzles, which could be arranged in anarray or any particular configuration. In embodiments comprising two ormore nozzles, the nozzles could be configured to move together and/orindependently.

Nozzle 118 may be configured with a nozzle aperture 119 that can beopened and/or closed to control the flow of material exiting from nozzle118. Specifically, nozzle aperture 119 may be in fluid communicationwith a nozzle channel 121 that receives a supply of material from amaterial source (not shown) within printing device 102. Some examples ofmaterials that may be received or used are disclosed in U.S. Pat. No.9,889,606, which is herein incorporated by reference in its entirety,hereinafter referred to as the “Tack and Drag case.”

In some embodiments, a worm-drive may be used to push the filament intonozzle 118 at a specific rate (which may be varied to achieve a desiredvolumetric flow rate of material from nozzle 118). In other embodiments,a worm-drive is omitted. For example, the material may be pulled fromnozzle 118 using an actuating system. It will be understood that in somecases, the supply of material could be provided at a location nearnozzle 118 (e.g., in a portion of nozzle assembly 116), while in otherembodiments the supply of material could be located at some otherlocation of printing device 102 and fed via tubes, conduits, or otherprovisions, to nozzle assembly 116.

As will be described below, printing system 100 can include provisionsfor facilitating the alignment of a printed design or graphic onto anarticle. In some embodiments, it may be useful to provide a user with away of aligning an article with printing system 100 so as to ensure agraphic is printed in the desired portion of the article. In particular,printing system 100 may include provisions for programming theorientation of an article with print device 102 in such a way as toaccommodate articles of various types, shapes, curves, and sizes.

In some embodiments, nozzle assembly 116 is associated with a firstactuating system 114. First actuating system 114 may include variouscomponents, devices, and systems that facilitate the motion of nozzleassembly 116 within housing 110. In particular, first actuating system114 may include provisions to move nozzle assembly 116 in any horizontaldirection (including but not limited to directions aligned with alongitudinal axis 124 and directions aligned with a lateral axis 126)and/or directions aligned with a vertical axis 122 to facilitatedepositing a material so as to form a three-dimensional object or toprint along a three-dimensional or curved surface. To this end,embodiments of first actuating system 114 may include one or moretracks, rails, and/or similar provisions to hold nozzle assembly 116 atvarious positions and/or orientations within housing 110. Embodimentsmay also include any kinds of motors, such as a stepper motor or a servomotor, to move nozzle assembly 116 along a track or rail, and/or to moveone or more tracks or rails relative to one another.

For purposes of this description, an object or article with a curvedsurface refers to articles with one or more portions that includecurves, bumps, and varying regions of thickness, such as articles 130 ofFIG. 1. For example, an article may have regions that are flat, smooth,level, or even, with relatively little thickness. However, the samearticle may also include curved regions with surfaces that deviate frombeing straight for some or all of its length or area. In someembodiments, a curved surface or curved area identifies a portion of anarticle that increases and/or decreases in height or thicknessassociated with the vertical axis of the article. In some embodiments,curved surfaces can comprise regular, geometric curves such as thoseassociated with circles, triangles, squares, and other geometric shapes,and/or they may also be irregular, for example in articles shaped toaccommodate or include a particular uneven configuration.

An actuating system can be configured to move a nozzle in one or moredirections. In some embodiments, an actuating system could move a nozzlein a single linear direction. In other embodiments, an actuating systemcould move a nozzle in at least two perpendicular directions. In stillother embodiments, an actuating system could move a nozzle in threeperpendicular directions. For example, in the exemplary embodiment shownin FIG. 1, first actuating system 114 may be configured to move nozzle118 in a first direction 160 (here, similar to an upward direction), asecond direction 161 (here, similar to a downward direction), a thirddirection 162, a fourth direction 163, a fifth direction 164, and asixth direction 165. As seen in FIG. 1, in some embodiments, firstdirection 160 and second direction 161 may be aligned with vertical axis122, and may generally represent opposing directions. Furthermore, thirddirection 162 and fourth direction 163 may be aligned with longitudinalaxis 124 in some embodiments, and may generally represent opposingdirections. In addition, fifth direction 164 and sixth direction 165 canbe aligned with lateral axis 126 in some embodiments, and may generallyrepresent opposing directions. Thus, third direction 162, fourthdirection 163, fifth direction 164, and sixth direction 165 canrepresent generally horizontally oriented directions (e.g., length andwidth directions), while first direction 160 and second direction 161can represent vertically oriented directions (e.g., height directions).Of course, while the exemplary embodiment depicts an actuating systemcapable of moving a nozzle through three independent x-y-z or Cartesiandirections, other embodiments may be configured to move a nozzle in sixindependent directions associated with a non-Cartesian coordinate system(e.g., a spherical coordinate system or a cylindrical coordinatesystem). Still further, in other cases an actuating system could move anozzle through six or more different directions that may not beorthogonal (e.g., directions of an oblique coordinate system).

In some embodiments, first direction 160 and/or second direction 161 maybe at a non-zero angle relative to a surface, such as base 112 or printsurface 148. For example, in FIG. 2, first direction 160 and seconddirection 161 are approximately normal to base 112. As used herein, adirection is approximately normal to a surface when it is within 10degrees from perpendicular to the surface. Thus, in differentembodiments, first direction 160, second direction 161, and/or nozzle118 may be at a non-zero angle relative to print surface 148 and/or base112.

For purposes of this discussion, a print surface may be associated withthe surface where a nozzle is printing. For purposes of this disclosure,print surface 148 refers to the surface of an article that receives oris attached to a printing material such as a composite yarn or othermaterial extruded or otherwise discharged or emitted from nozzle 118during printing. For example, in cases where nozzle 118 prints directlyonto base 112, the print surface is associated with or comprises asurface of base 112. In the embodiment of FIG. 1, print surface 148 isillustrated as the side of base 112 that faces upward toward nozzleassembly 116. However, it should be noted that in other embodiments,print surface 148 may comprise the surface or side of an article orobject that is printed upon by nozzle 118. Print surface 148 may begenerally flat, or it may be substantially curved and include contours.In one embodiment, print surface 148 may be the side or surface of anobject or article that is generally normal relative to vertical axis122. However, in other embodiments, for example in cases where thearticle is non-flat, print surface 148 may not be normal relative tovertical axis 122.

In certain embodiments, printing system 100 can selectively move nozzle118. In one embodiment, printing system 100 simultaneously moves nozzle118 in directions aligned with three different axes, as noted above. Inone example, printing system 100 may move nozzle 118 in first direction160 away from base 112, while simultaneously moving nozzle 118 in thirddirection 162 and/or in fifth direction 164 over print surface 148. Inanother example, a position along a direction is maintained whileprinting system 100 selectively moves nozzle 118 in another direction.Printing system 100 may move nozzle 118 in second direction 161 towardprint surface 148 while simultaneously maintaining a base position ofnozzle 118 along longitudinal axis 124 and lateral axis 122 over printsurface 148. For example, printing system 100 may move nozzle 118 infirst direction 160 away from base 112 while simultaneously maintaininga base position of nozzle 118 in third direction 162, fourth direction163, fifth direction 164, and sixth direction 165 (i.e., remainingstationary with respect to those directions). In another example,printing system 100 may maintain a print distance 216 (see FIG. 2) fromnozzle 118 with respect to vertical axis 122 while simultaneously movingnozzle 118 parallel to print surface 148 in a horizontal direction(e.g., third direction 162, fourth direction 163, fifth direction 164,and sixth direction 165).

For purposes of this description, print distance 216 (as shown in FIG.2) refers to the distance or height extending along vertical axis 122between nozzle 118 and print surface 148. Thus, in some embodiments, asprint surface 148 may be curved or otherwise vary in height, printdistance 216 may increase or decrease without any corresponding verticalmotion of nozzle 118 when nozzle moves in the horizontal plane. In otherwords, print distance 216 may change even though the distance betweennozzle 118 and base 112 remains constant due to the contoured geometryof an underlying article. In other embodiments, print distance 216 mayremain constant as nozzle 118 moves in the horizontal plane. In oneembodiment, due to a vertical motion of nozzle 118, the distance betweennozzle 118 and base 112 may vary while nozzle 118 maintains a constantprint distance 216 relative to print surface 148. Thus, printing system100 can maintain a generally constant distance between nozzle 118 andprint surface 148, which can facilitate printing directly to objectswith some curvature and/or surface texture.

In different embodiments, one or more articles 130 can be associatedwith a second actuating system 190 that may be included in printingsystem 100. Second actuating system 190 may include various components,devices, and systems that facilitate the motion of articles 130 withinhousing 110. Although the exemplary embodiment depicts a particularrectangular box-like geometry for second actuating system 190, otherembodiments could use any system having any geometry and/or design. Theshape and size of the actuating system could vary according to factorsincluding the article being printed on, the size and shape of parts thatmay be formed within printing device 102, as well as possibly otherfactors.

In particular, second actuating system 190 may include provisions tomove articles 130 in any horizontal direction and/or vertically orienteddirection to facilitate the position of articles 130 underneath nozzle118 for printing along a three-dimensional surface. To this end,embodiments of second actuating system 190 may include one or moretracks, rails, and/or similar provisions to hold articles 130 at variouspositions and/or orientations within housing 110. Embodiments may alsoinclude any kinds of motors, such as a stepper motor or a servo motor,to move articles 130 along a track or rail, and/or to move one or moretracks or rails relative to one another. In some embodiments, there maybe a securing device 192, such as a clamp, claw, or other adjustablegripping member, in second actuating system 190 to provide a means ofattachment between second actuating system 190 and articles 130. Inother embodiments, there may be no securing device 192. It should benoted that portions of second actuating system 190 may be positioned invarious locations within printing system 100 in order to provide thenecessary orientation to articles 130.

Thus, second actuating system 190 can be configured to move an articlein one or more directions. In some embodiments, an actuating systemcould move an article in a single linear direction, or two lineardirections. In other embodiments, an actuating system could move anarticle in at least two perpendicular directions. In still otherembodiments, an actuating system could move an article in at least threeperpendicular directions. For example, in the exemplary embodiment shownin FIG. 1, second actuating system 190 may be configured to movearticles 130 in first direction 160, second direction 161, thirddirection 162, fourth direction 163, fifth direction 164, and sixthdirection 165. As seen in FIG. 1, first direction 160 and seconddirection 161 may be associated with a vertical axis of housing 110,while third direction 162, fourth direction 163, fifth direction 164,and sixth direction 165 may be associated with horizontal directions ofhousing 110 (e.g., length and width directions). Of course, while theexemplary embodiment depicts second actuating system 190 capable ofmoving an article through three independent x-y-z or Cartesiandirections, other embodiments may be configured to move an article insix independent directions associated with a non-Cartesian coordinatesystem (e.g., a spherical coordinate system or a cylindrical coordinatesystem). Still further, in other cases an actuating system could move anarticle through six different directions that may not be orthogonal(e.g., directions of an oblique coordinate system).

In certain embodiments, printing system 100 may selectively move thearticle using second actuating system 190 or another mechanism. In oneembodiment, printing system 100 may move an article in three directionssimultaneously. For example, printing system 100 may move articles 130in first direction 160 away from base 112 while simultaneously movingarticles 130 in third direction 163 and/or in fifth direction 164 in adirection generally parallel to base 112. In other embodiments, aposition along one direction is maintained while printing system 100selectively moves articles 130 in another direction. In certainembodiments, printing system 100 may move articles 130 with respect tovertical axis 122 away from or toward base 112 while simultaneouslymaintaining a base position of articles 130 with respect to lateral axis126 and longitudinal axis 124. For example, printing system 100 may movearticles 130 in first direction 160 away from base 112 whilesimultaneously maintaining a base position of articles 130 in thirddirection 162, fourth direction 163, fifth direction 164, and sixthdirection 165. In some embodiments, printing system 100 may maintainprint distance 216 from articles 130 along vertical axis 122 whilesimultaneously moving articles 130 parallel to the base of housing 110.For example, printing system 100 may maintain print distance 216 fromarticles 130 along vertical axis 122 while simultaneously movingarticles 130 in directions aligned with lateral axis 126 andlongitudinal axis 124.

In some embodiments, components of printing system 100 associated withsecond actuating system 190 may be specifically adapted to securearticles 130 in a fixed position or orientation. For example, someembodiments may include various kinds of mounting devices, harnesses,temporary adhesives, or other provisions that may temporarily fix orhold the position of an article relative to housing 110. Such provisionsmay help precisely orient a specific portion of an article towardsnozzle 118 (and correspondingly towards other components of printingdevice 102). For example, some embodiments could utilize a harness thatfixes the orientation and position of an article over base 112 so that athree-dimensional design can be printed onto any desired portion of anarticle, such as an article of footwear. These provisions may alsoreduce the tendency of an article to move or jostle as the position ofbase 112 is adjusted, or nozzle 118 extrudes a print material ontoarticles 130.

Furthermore, in some embodiments, second actuating system 190 or anothermechanism of printing system 100 may rotate or reposition articles 130in a horizontal plane about a horizontal axis oriented with respect tovertical axis 122, or in a vertical plane about a vertical axis orientedwith respect to longitudinal axis 124 and/or lateral axis 126. Forexample, in some embodiments, there may be a mechanism allowing betweenabout a 10 and about a 90 degree rotation of articles 130. In otherembodiments, there may be a mechanism allowing at least about a 180degree rotation of articles 130. In one embodiment, there may be amechanism that allows about a 360 degree rotation. In other embodiments,there may be between about a 180 and about a 360 degree rotation ofarticles 130 in printing system 100. For example, in one embodiment,printing system 100 may include provisions for rotation of articles 130in the horizontal plane about a horizontal axis oriented with respect tovertical axis 122. In another embodiment, printing system 100 mayinclude provisions for rotation of articles 130 in the vertical planeabout a vertical axis oriented with respect to longitudinal axis 124and/or lateral axis 126. In some embodiments, printing system 100 mayinclude provision for rotation of articles 130 in both the horizontaland vertical planes. In one embodiment, repositioning movement ofarticles 130 may not be circular (i.e., rotational), and instead mayinvolve a non-circular, linear, or otherwise irregular repositioning ofarticles 130.

Thus, in some embodiments, articles 130 may be oriented in multiplepositions in housing 110 during printing. It should be noted that firstactuating system 114 and second actuating system 190 may be operatedsimultaneously or independently during use of printing system 100. Inaddition, first actuating system 114 and second actuating system 190 maybe connected in such a way so as to allow both to operate in conjunctionwith one another during printing. Furthermore, in some embodiments,printing device 102 may include base 112 that can move independently ofsecond actuating system 190. In other embodiments, second actuatingsystem 190 may be fixed to base 112 such that the components move oroperate in concert. In one embodiment, there may be no base, such thatsecond actuating system 190 operates to move an article that isindependent of a platform or tray surface.

In some embodiments, repositioning may be initiated or performed by auser. For example, in some embodiments, first actuating system 114and/or second actuating system 190 can be operated manually by a user.In other embodiments, repositioning of articles 130 may occur in anautomated manner by printing system 100. For example, there may beprovisions for automating the operation of first actuating system 114and second actuating system 190. In one example, some embodiments couldinclude motors and/or other provisions for automatically driving nozzle118 to various positions along one or more tracks. Moreover, inautomated embodiments, the position or speed of nozzle 118 and/orarticles 130 could be adjusted using controls provided in printingsystem 100, or using an associated system, such as computing system 104,which is discussed in further detail below.

It will be understood that for purposes of illustration, the components,devices and systems of printing device 102 are shown schematically inFIG. 1. It will therefore be appreciated that embodiments may includeadditional provisions not shown, including specific parts, components,and devices that facilitate the operation of first actuating system 114,second actuating system 190, and nozzle assembly 116. For example, firstactuating system 114 is shown schematically as including several tracksor rails, but the particular configuration and number of partscomprising first actuating system 114 may vary from one embodiment toanother.

As discussed above, printing system 100 can include provisions tocontrol and/or receive information from printing device 102. Theseprovisions can include a computing system 104 and a network 106.Generally, the term “computing system” refers to the computing resourcesof a single computer, a portion of the computing resources of a singlecomputer, and/or two or more computers in communication with oneanother. Any of these resources can be operated by one or more humanusers. In some embodiments, computing system 104 may include one or moreservers. In some cases, a print server may be primarily responsible forcontrolling and/or communicating with printing device 102, while aseparate computer (e.g., desktop, laptop, or tablet) may facilitateinteractions with a user. Computing system 104 can also include one ormore storage devices including but not limited to magnetic, optical,magneto-optical, and/or memory, including volatile memory andnon-volatile memory.

In the exemplary embodiment of FIG. 1, computing system 104 may comprisea central processing device 185, a viewing interface 186 (e.g., amonitor or screen), input devices 187 (e.g., keyboard and mouse), andsoftware for designing a computer-aided design (“CAD”) representation189 of a printed structure. In at least some embodiments, the CADrepresentation 189 of a printed structure may include not onlyinformation about the geometry of the structure, but also informationrelated to the materials required to print various portions of thestructure.

In some embodiments, computing system 104 may be in direct contact withprinting device 102 via network 106. Network 106 may include any wiredor wireless provisions that facilitate the exchange of informationbetween computing system 104 and printing device 102. In someembodiments, network 106 may further include various components such asnetwork interface controllers, repeaters, hubs, bridges, switches,routers, modems and firewalls. In some cases, network 106 may be awireless network that facilitates wireless communication between two ormore systems, devices, and/or components of printing system 100.Examples of wireless networks include, but are not limited to: wirelesspersonal area networks (including, for example, Bluetooth), wirelesslocal area networks (including networks utilizing the IEEE 802.11 WLANstandards), wireless mesh networks, and mobile device networks, as wellas other kinds of wireless networks. In other cases, network 106 couldbe a wired network including networks whose signals are facilitated bytwisted pair wires, coaxial cables, and optical fibers. In still othercases, a combination of wired and wireless networks and/or connectionscould be used.

Printing system 100 may be operated as follows to form one or morestructures using a 3D printing, or additive, process. Computing system104 may be used to design a structure. This may be accomplished usingsome type of CAD software, or other kind of software. The design maythen be transformed into information that can be interpreted by printingdevice 102 (or a related print server in communication with printingdevice 102). In some cases, the design may be converted to a 3Dprintable file, such as a stereolithography file (STL file).

Before printing, an article may be placed onto base 112 or may besecured using second actuating system 190. Once the printing process isinitiated (by a user, for example), printing device 102 may begindepositing material onto the article. This may be accomplished by movingnozzle 118 (using first actuating system 114) to build up layers of astructure using deposited material. In embodiments where fused filamentfabrication is used, material extruded from nozzle 118 may be heated soas to increase the pliability of the heat moldable material as it isdeposited.

Although some of the embodiments shown in the figures depict a systemusing filament fused fabrication printing technologies, it will beunderstood that still other embodiments could incorporate one or moredifferent 3D printing technologies. For example, printing system 100 mayuse a tack and drag print method, as described in the Tag and Drag case.Moreover, still other embodiments could incorporate a combination offilament fused fabrication and another type of 3D printing technique toachieve desired results for a particular printed structure or part.

In different embodiments, printing device 102 may use a variety ofdifferent materials for forming 3D parts, including, but not limited to:thermoplastics (e.g., polyactic acid and acrylonitrile butadienestyrene), high density polyethylene, eutectic metals, rubber, clays(including metal clays), Room Temperature Vulcanizing silicone (RTVsilicone), and porcelain, as well as possibly other kinds of materialsknown in the art. In embodiments where two or more different printed orextruded materials are used to form a part, any two or more of thematerials disclosed above could be used. In some embodiments, printingdevice 102 may extrude, discharge or use a material or thread and/oryarn composition as described in U.S. Pat. No. 9,410,270, which isherein incorporated by reference in its entirety, and is hereinafterreferred to as the “Thread Structure Composition” case.

As discussed above, in some embodiments, printed structures may beprinted directly to one or more articles 130. The term “articles” isintended to include both articles of footwear (e.g., shoes) and articlesof apparel (e.g., shirts and pants), as well as various other objects.As used throughout this disclosure, the terms “article of footwear” and“footwear” include any footwear and any materials associated withfootwear, including an upper, and may also be applied to a variety ofathletic footwear types, including baseball shoes, basketball shoes,cross-training shoes, cycling shoes, football shoes, tennis shoes,soccer shoes, and hiking boots, for example. As used throughout thisdisclosure, the terms “article of footwear” and “footwear” also includefootwear types that are generally considered to be nonathletic, formal,or decorative, including dress shoes, loafers, sandals, slippers, boatshoes, and work boots.

While the disclosed embodiments are described in the context offootwear, the disclosed embodiments may further be equally applied toany article of clothing, apparel, or equipment that includes 3Dprinting. For example, the disclosed embodiments may be applied to hats,caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments,athletic support garments, gloves, wrist/arm bands, sleeves, headbands,any knit material, any woven material, any nonwoven material, sportsequipment, etc. Thus, as used throughout this disclosure, the term“article of apparel” may refer to any apparel or clothing, including anyarticle of footwear, as well as hats, caps, shirts, jerseys, jackets,socks, shorts, pants, undergarments, athletic support garments, gloves,wrist/arm bands, sleeves, headbands, any knit material, any wovenmaterial, any nonwoven material, etc. As used throughout thisdisclosure, the terms “article of apparel,” “apparel,” “article offootwear,” and “footwear” may also refer to a textile, a natural fabric,a synthetic fabric, a knit, a woven material, a nonwoven material, amesh, a leather, a synthetic leather, a polymer, a rubber, and a foam.

In an exemplary embodiment, printing device 102 may be configured toprint one or more structures directly onto a portion of one of articles130. Articles 130 comprise exemplary articles that may receive a printedstructure directly from printing device 102, for example including anarticle of footwear 132, a helmet 136, or a glove 134, each of which hasa three-dimensional configuration. Articles 130 may also include anupper or a t-shirt, which have a flattened configuration. Thus, it willbe understood that printing device 102 may be used to apply printedmaterial to articles 130 in three-dimensional configurations and/orflattened configurations.

In order to apply printed materials directly to one or more articles,printing device 102 may be capable of printing onto the surfaces ofvarious kinds of materials. Specifically, in some cases, printing device102 may be capable of printing onto the surfaces of various materialssuch as a textile, a natural fabric, a synthetic fabric, a knit, a wovenmaterial, a nonwoven material, a mesh, a leather, a synthetic leather, apolymer, a rubber, and a foam, or any combination thereof, without theneed for a release layer interposed between a substrate and the bottomof the printed material, and without the need for a perfectly ornear-perfectly flat substrate surface on which to print. For example,the disclosed methods may include printing a resin, acrylic,thermoplastic material, or ink material onto a fabric, for example, aknit material, where the material is adhered or bonded to the fabric andwhere the material does not generally delaminate when flexed, rolled,worked, or subjected to additional assembly processes or steps. As usedthroughout this disclosure, the term “fabric” may be used to refergenerally to materials chosen from any textile, natural fabric,synthetic fabric, knit, woven material, nonwoven material, mesh,leather, synthetic leather, polymers, rubbers, foam, and combinationsthereof.

Although some embodiments may use printing device 102 to printstructures directly onto the surface of a material, other embodimentsmay include steps of printing a structure onto a tray, base, or releasepaper, and then joining the printed structure to an article in aseparate step. In other words, in at least some embodiments, printedstructures need not be printed directly to the surface of articles 130.

As previously noted, printing device 102 may be configured to printdirectly onto various articles 130. Similarly, printing device 102 maybe configured to print on various surface topographies. For example, asshown in FIG. 2, a three-dimensional (non-flat) first article 204 isdepicted. In FIG. 2, first article 204 includes a forefoot region 210, amidfoot region 212, and a heel region 214, as described above.Furthermore, first article 204 includes a medial side 206 and a lateralside 208.

In other embodiments, first article 204 can include one or moreprotrusions and/or cavities, curves, contours, and other non-flatsurfaces. Moreover, printing device 102 may print on surfaces havingvarious shapes. For example, as shown, first article 204 is a generallyoblong, irregularly shaped object, comprising a partially assembledupper for an article of footwear. In other embodiments, first article204 may include a variety of three-dimensional contours, geometries, orshapes, including, for example, circular geometries, triangulargeometries, rectangular geometries, sock-like geometries, sandal-likegeometries, irregularly shaped geometries, or geometries correspondingto other components for an article of footwear. As shown in FIG. 2,first article 204 includes print surface 148 that faces toward nozzle118, as well as a lower surface (not shown) that is in contact with base112.

In some embodiments, the horizontal or vertical position of articles 130may be adjusted using a sensor 218. Sensor 218 may be adjacent to nozzle118 in some embodiments. Sensor 218 may help to align the position ofarticles 130 with print nozzle 118. In other words, sensor 218 mayprovide printing system 100 with a mechanism for determining themovement of articles 130 relative to nozzle 118, for example, duringrepositioning of articles 130 in any of the usual x, y, and z spatialdirections as described above with reference to the actuating systems.Moreover, some cases may include steps of adjusting nozzle 118 to betteralign nozzle 118 with the selected surface of articles 130 that will beprinted on. Thus, in some embodiments, printing system 100 may includesensor 218 that provides printing system 100 with information regardingthe position of articles 130 and/or nozzle 118. Sensor 218 may operatein conjunction with computing system 104 to provide greater automationto printing system 100.

It should be noted that in some embodiments, base 112 may be removed andarticles 130 may be secured by other means in printing device 102. Forexample, article of footwear 132 may be attached to a device orcomponent that holds article of footwear 132 in position within printingdevice 102, such as securing device 192. Securing device 192 may be partof second actuating system 190, or may be a separate device. In oneembodiment, securing device 192 can be moved or rotated such that firstarticle 204 changes orientation or position, permitting nozzle 118 toprint along substantially all areas and surfaces of first article 204.As shown in FIG. 2, securing device 192 may be used to hold, grip, orreposition first article 204.

As previously mentioned, nozzle 118 is configured to extrude variousmaterials. For example, as shown, nozzle 118 may extrude a substantiallyelongated continuous composite yarn 202, or nozzle 118 may extrudemultiple elongated continuous composite yarn segments. A composite yarnmay include a composition as described in the Thread StructureComposition case. For example, in some embodiments, composite yarn 202may include a melt resistant material and/or a heat moldable material.As used herein, heat moldable material includes thermoplastic. In someembodiments, a composite yarn is at least partially formed ofthermoplastic.

It should be noted that in different embodiments, the print material maybe ejected or otherwise emitted via nozzle 118 in the form of droplets.One of ordinary skill in the art will recognize that the form of thedroplets may vary depending on the actual material ejected or otherwiseemitted from nozzle 118. In some embodiments, the droplets may thus beany viscosity liquid material, or even a semi-solid material. Consistentwith an embodiment, the droplets may be any desired material or phase ofmaterial suitable for use in printing system 100.

In different embodiments, a continuous segment of composite yarn 202extends over base 112 of printing device 102 including first article204. For example, composite yarn 202 extends over a curved surface 200in FIG. 2. A composite yarn 202 or other printing material may beattached to curved surface 200 using various techniques and variousmaterials. In some embodiments, a heat moldable material bonds directlyto the attaching surface. Additionally, in certain embodiments, the heatmoldable material bonds to a melt resistant material.

In some embodiments, a heating system is configured to heat a portion ofcomposite yarn 202 into a liquid state. Accordingly, in variousembodiments, printing system 100 may be configured to force a portion ofcomposite yarn 202 onto curved surface 200 by moving nozzle 118 alongvarious directions (see FIGS. 3-10). Composite yarn 202 may thentransition from the liquid state to a solid state to bond with anattaching surface. As discussed below, nozzle 118 may maintain printdistance 216 between nozzle 118 and a curved surface 200 to allowcomposite yarn 202 to bond with curved surface 200 (see FIGS. 3-10).

In FIGS. 3-18, a portion of printing system 100 is depicted. Forpurposes of convenience some components of printing system 100 are notshown. It should be understood that FIGS. 3-18 are for purposes ofillustration only, and the components described above with respect toFIGS. 1 and 2 may be included or referred to in the followingdescription while not illustrated in the figures. As shown in thefigures, in different embodiments, securing device 192 may be used tohold, grip, or reposition the article or print surface 148. In otherembodiments, a different component or system may be used to hold,rotate, or reposition the articles.

In some instances it is desirable to print directly along the surface ofan object or articles 130 that includes contours, or isthree-dimensionally configured. Selectively attaching composite yarn 202along a curved surface 200 can allow formation of designs, structures,and other features directly onto a pre-assembled or pre-made object.FIGS. 3-10 illustrate embodiments of methods of printing a materialalong a series of curved surfaces of a second article 300. The methodsillustrated may be implemented on various devices, may utilize variousmaterials, and use different types of bases. Accordingly, the exemplarymethods illustrated in FIGS. 3-10 are for illustrative purposes only. Insome embodiments, the printing can occur over articles 130 that havebeen previously manufactured or fabricated, or partially manufactured,and printing can occur post-manufacture. This can allow customization ofarticles 130 to be processed more quickly, as well as morecost-efficiently. Furthermore, printing system 100 can allow formationof designs that encompass multiple surfaces and curves of article 130,including surfaces comprising varying materials, and can provide moreseamless design appearance.

In FIG. 3, second article 300 is disposed in a first position 302 withinhousing 110 (not shown) such that a portion of medial side 206 ispresented as print surface 148 to nozzle 118. Nozzle 118 has begun todeposit composite yarn 202 in a direction generally aligned withlongitudinal axis 124 of second article 300. Specifically, nozzle 118deposits composite yarn 202 along heel region 214 of medial side 206 ofsecond article 300. In FIG. 4, nozzle 118 is continuing to move in adirection generally aligned with longitudinal axis 124 and has movedtoward midfoot region 212.

As described with reference to FIG. 2, in some embodiments, printingsystem 100 maintains print distance 216 between nozzle 118 and printsurface 148 to allow attachment of composite yarn 202 along curvedsurface 200. First actuating system 114 (shown in FIG. 1) may allowmovement of nozzle 118 in multiple directions. Some embodiments may useone or more features of U.S. Publication Number 2017/0129178, which isherein incorporated by reference in its entirety.

For example, nozzle 118 may be moved in first direction 160 or seconddirection 161 (i.e., nozzle 118 may move up and down relative to base112). As shown in a magnified area 402 in FIG. 4, in one embodiment,printing system 100 can maintain a constant print distance 216 betweennozzle 118 and print surface 148. In other embodiments, composite yarn202 may be pushed into print surface 148, and composite yarn 202 maybond with print surface 148 as composite yarn 202 is prodded or tackedonto print surface 148. In such embodiments, print distance 216 maydecrease as nozzle 118 is prodded into print surface 148, while printdistance 216 may increase as nozzle 118 recedes from print surface 148following prodding.

It should be noted that in some embodiments, composite yarn 202 is notpushed into print surface 148, and so print distance 216 may remainrelatively constant during printing. For example, composite yarn 202 maybond with print surface 148 once composite yarn 202 has been depositedon print surface 148 from a constant print distance 216. Bonding mayoccur in some embodiments as a result of the composition of compositeyarn 202 or other features of printing system 100.

In different embodiments, print distance 216 may comprise varyingdistances. In some embodiments, print distance 216 may be selected by auser through central processing device 185, as illustrated in FIG. 1. Inone embodiment, print distance 216 is greater than a thickness ofcomposite yarn 202. In some embodiments, print distance 216 may be lessthan the thickness of composite yarn 202 in cases where composite yarn202 is being pushed or prodded onto print surface 148.

In certain instances it may be desirable to move nozzle 118 along printsurface 148 of second article 300 while maintaining a generally constantprint distance 216 between nozzle 118 and print surface 148. Forexample, to allow the flow of composite yarn 202 along athree-dimensional curved surface 200 in a generally smooth andconsistent manner, print distance 216 may remain generally constant asnozzle 118 moves along print surface 148. In some embodiments, as shownin FIGS. 3-7, printing system 100 moves nozzle 118 along print surface148 in a direction generally aligned with longitudinal axis 124 whilemaintaining a constant print distance 216 between nozzle 118 and printsurface 148.

In different embodiments, composite yarn 202 may be disposed, attached,printed, or otherwise joined to any non-flat areas and/or flat areas ofprint surface 148 as composite yarn 202 is released or extruded.Composite yarn 202 may bond with print surface 148, thereby allowing forprinting along one or more curved surfaces 200 (e.g., as shown inmagnified area 402). In other embodiments, the printing method appliedto curved surface 200 may feature one or more of the methods describedin the Tack and Drag case.

Thus, in different embodiments, printing system 100 may be configured toposition or attach a thread or composite yarn onto any portions of anarticle that include various curved surfaces 200. In some embodiments,printing system 100 moves nozzle 118 toward and/or over second article300. For example, as shown in FIG. 3, printing system 100 moves nozzle118 along third direction 162, fourth direction 163, fifth direction164, and/or sixth direction 165 as it deposits composite yarn 202 alongprint surface 148. As shown in FIG. 4, in certain instances it may bedesirable to move nozzle 118 along print surface 148 while maintaining aconstant print distance 216 between nozzle 118 and print surface 148 toallow attachment of composite yarn 202 to second article 300.

For example, as shown in FIGS. 3-7, printing system 100 maintains aconstant print distance 216 between nozzle 118 and print surface 148 bymoving nozzle 118 in first direction 160 or second direction 161 asnozzle moves in the horizontal plane. As such, composite yarn 202 isdeposited along print surface 148 and composite yarn 202 can bond withprint surface 148, thereby allowing for three-dimensional surfaceprinting. For example, as seen in magnified area 402 of FIG. 4,composite yarn 202 is being laid along a first curved area 404. Byadjusting height of nozzle 118 along vertical axis 122, nozzle 118maintains a constant print distance 216 and composite yarn 202 can belaid or deposited along first curved area 404 in a stable, smooth,continuous manner. It should be noted that in other embodiments, printdistance 216 may be increased or decreased over different portions ofsecond article 300 while maintaining print quality.

In FIG. 5, nozzle 118 has moved farther toward forefoot region 210 alonga direction generally aligned with longitudinal axis 124. In someembodiments, it may be desired to continue printing along a differentside or surface of second article 300. In some cases, for example,printing may be desired along the bottom surface, or sole region, ofsecond article 300. In FIG. 6, the orientation of second article 300 hasbeen changed to allow a sole region 600 to comprise print surface 148.In other words, in some embodiments, second article 300 may be rotatedor otherwise re-oriented to accommodate or provide various areas ofsecond article 300 to nozzle 118. In one embodiment, the repositioningmay be performed by second actuating system 190 (discussed in referenceto FIG. 1)

In FIG. 6, second article 300 is disposed in a second position 602within housing 110 (not shown) so that sole region 600 is presented asprint surface 148 to nozzle 118. Nozzle 118 has begun to depositcomposite yarn 202 in a direction generally aligned with longitudinalaxis 124 along forefoot region 210 of sole region 600 of second article300. In FIG. 7, nozzle 118 is continuing to move in a directiongenerally aligned with longitudinal axis 124 and has moved past midfootregion 212 into heel region 214.

Similarly, in some embodiments, it may be desired to continue printingalong a different side or surface of second article 300. In some cases,for example, printing may be desired along lateral side 208 of secondarticle 300. In FIG. 8, the orientation of second article 300 has beenchanged to allow lateral side 208 to comprise print surface 148. Inother words, in some embodiments, second article 300 may be rotated orotherwise re-oriented to accommodate or provide different areas ofsecond article 300 to nozzle 118. In FIG. 8, second article 300 isdisposed in a third position 802 within housing 110 (not shown) so thatlateral side 208 is presented as print surface 148 to nozzle 118. Nozzle118 has deposited composite yarn 202 in a direction generally alignedwith longitudinal axis 124 from heel region 214 toward forefoot region210 of lateral side 208 of second article 300. Thus, in differentembodiments, printing system 100 may print along three-dimensionalobjects, articles, and various curved or non-flat surfaces.

In FIG. 9, a magnified area of a portion of second article 300 isdepicted. Nozzle 118 is shown as it moves in fourth direction 163 alonga curved region 900. Nozzle 118 is at a first height 906 above a firstsurface 904. In this case, first height 906 is substantially similar toprint distance 216. In FIG. 10, nozzle 118 begins to move upward alongfirst direction 160 during its motion in fourth direction 163 in orderto accommodate a slope comprising a second surface 1000 in curved region900. As nozzle 118 moves along second surface 1000, the height of nozzle118 relative to first surface 904 is increasing. The change in height isdepicted as nozzle 118 shifts from first height 906 and increases to asecond height 1002 relative to first surface 904. Composite yarn 202 isdeposited along the slope while nozzle 118 maintains a relativelyconstant print distance 216 from print surface 148 of second article300.

FIG. 11 depicts nozzle 118 having completed printing of composite yarn202 along second surface 1000 and beginning printing along a relativelyflat third surface 1102. There is no longer movement of nozzle 118 infirst direction 160 or second direction 161 while the movement of nozzle118 continues along fourth direction 163 over third surface 1102. Inthis stage, nozzle 118 has increased to a third height 1100 relative tofirst surface 904. Third height 1100 is greater than both first height906 and second height 1002. In other embodiments, a curved region mayinclude different curves and nozzle 118 may move downward in a directionaligned with vertical axis 122 (i.e., second direction 161). In someembodiments, while nozzle 118 may vary in height relative to differentcontoured portions or surfaces of articles 130, print distance 216 maybe maintained at a constant distance, as illustrated in FIGS. 9-11. Inother embodiments, nozzle 118 may move along print surface 148 in firstdirection 160 and/or second direction 161 while it also moves in ahorizontally oriented direction, and print distance 216 may also beeither increased or decreased.

It should be noted that while the illustrations included herein depictfirst position 302, second position 602, and third position 802 asstationary, the rotation or movement of second article 300 may becontinuous throughout printing. In one embodiment, second article 300may be rotated or otherwise moved (for example, by second actuatingsystem 190, shown in FIG. 1) at different times or different pointsduring printing. In some embodiments, second article 300 may be turned,moved, or rotated for continuous or intermittent periods of time toprovide an optimal print surface 148 to nozzle 118. Adjustments in thepositioning or orientation of second article 300 may provide improvedprint quality and a better attachment of composite yarn 202 to athree-dimensional surface.

As previously noted, the various embodiments allow for any number ofattaching surfaces, such as print surface 148. Thus, differentthree-dimensional structures can be formed along contoured orthree-dimensional surfaces. In some embodiments, structures can beformed using any of the methods described in U.S. Publication Number2014/0020192 to Jones et al., published Jan. 23, 2014 and titled“Footwear Assembly Method with 3D Printing,” the disclosure of which isherein incorporated by reference in its entirety. It should beunderstood that in cases where print surface 148 is non-flat, articles130 may be repositioned to provide nozzle 118 with an optimal printingsurface. In other words, articles 130 may move, rotate, or otherwiseadjust position in order to accommodate the movement of nozzle 118, asdescribed with reference to FIGS. 1-11. Thus, in the embodimentsdiscussed below, articles 130 may be moved between first position 302,second position 602, and other positions in order to allow, for example,nozzle 118 to form three-dimensional structures along any curvedsurfaces of articles 130.

For example, in some embodiments, one or more traction elements may beformed along a portion of an article. In one embodiment, one or morecleats 1204 may be printed. FIGS. 12-17 illustrate isometric views of aprinting sequence of multiple 3D layers forming a series of cleats 1204.In different embodiments, cleats 1204 may be printed along irregular,curved, or otherwise substantially non-flat surfaces. Nozzle 118 mayaccommodate the varying curvature of print surface 148 during printing.

As previously mentioned, nozzle 118 is configured to extrude variousmaterials. For example, as shown, nozzle 118 may extrude a substantiallyelongated continuous composite yarn 202, or nozzle 118 may extrudemultiple elongated continuous thread segments. Composite yarn 202 mayinclude a composition as described in the embodiments of the ThreadStructure Composition case.

In different embodiments, nozzle 118 may move in directions aligned withvertical axis 122, directions aligned with longitudinal axis 124,direction aligned with lateral axis 126, or other directions, in orderto print along a curved surface, as described with respect to FIGS.1-11. In other words, the printing of three-dimensional structures alongthree-dimensional or substantially contoured surfaces may be providedthrough application and use of printing system 100. Thus, in someembodiments, three-dimensional structures may be formed along differenttypes of articles during varying points of the manufacture of thearticles. For example, a structure may be printed on a partially formedarticle in some embodiments. In other embodiments, a structure may beprinted on a fully formed or manufactured article. In one embodiment, anupper may be formed and shaped (for example, over a last) using anyprocess known in the art, and subsequently there may be additionalstructures formed or printed over the upper using printing system 100.

In FIGS. 12-17, cleats 1204 are being formed along an outer curvedsurface of a sole structure 1202 (“curved surface” 1202) of a thirdarticle 1200. FIG. 12 illustrates a printed material 1210 beingdeposited onto curved surface 1202 near forefoot region 210. In FIG. 12,a series of cleats 1204 have been formed along heel region 214 andmidfoot region 212. A first portion 1212 of a first layer 1214 has beenprinted on curved surface 1202. It should be noted that first portion1212 and print surface 148 may be joined, attached, bound, coupled, orotherwise connected through one of the techniques described in theThread Structure Composition case. For example, in one embodiment, heatmay be applied during the printing process, forming a melted layer ofmaterial between first portion 1212 and print surface 148. The meltedlayer may bond first portion 1212 (or portions thereof) to print surface148.

Printed material 1210 may be ejected or otherwise emitted from nozzle118 in the form of droplets, thread, yarn, or any viscosity liquidmaterial or a semi-solid material. Printed material 1210 may be anydesired material or phase of material suitable for use in printingsystem 100 as described above.

One of ordinary skill in the art will recognize that the printed layersforming printed material 1210 may originate with different materials,colors, chemistries, optional fillers, etc., in order to fully customizethe desired properties of third article 1200. Printed material 1210 mayalso comprise layers having gradients of colors blended amongst thelayers, or may comprise gradients of elasticity due to variations inmaterial ejected from nozzle 118 during printing of printed material1210. For example, printed material 1210 may comprise layers of lowelasticity printed material alternated or in conjunction with layers ofhigh elasticity material, as described in the Tack and Drag case.

One of ordinary skill in the art will also recognize that the printedlayers forming printed material 1210 may comprise layers of materialhaving at least a first color alternated or in conjunction with layershaving at least a second color. For example, printed material 1210 maybe designed to impart high strength and low elasticity in heel region214, while maintaining high elasticity and flexibility in forefootregion 210, and such properties may be accomplished by varying theproperties of printed material 1210 through printing of differentcombinations of materials and layers in any desired manner on anysurface of third article 1200.

In different embodiments, the three-dimensional printed structures maybe various shapes and sizes, and may be disposed along different areasand types of surfaces of third article 1200. For example, in FIG. 12,cleats 1204 include a first cleat 1206 and a second cleat 1208. Firstcleat 1206 and second cleat 1208 are generally rounded cylindricalshapes. In the embodiment of FIG. 12, first cleat 1206 is largerrelative to second cleat 1208. In addition, first cleat 1206 includes ahollow interior area, whereas second cleat 1208 has a solid orcontinuous interior volume and surface. Furthermore, second cleat 1208has been formed along a substantially curved area of heel region 214,whereas first cleat 1206 has been formed along a relatively flat area ofheel region 214. In other embodiments, first cleat 1206 and second cleat1208 may be larger or smaller, may be other geometric or irregularthree-dimensional shapes, and may be located along other areas of thirdarticle 1200.

In some embodiments, referring to FIGS. 13 and 14, first segment 1300may be cured by UV light. However, in other embodiments, first segment1300 may be deposited without the need to cure the deposited material.Depending on the material used for printing of printed material 1210,the material may be deposited in a liquid, semi-liquid, or otherwisegel-like or viscous phase. The material may then be solidified, at leastpartially, or cured, for various reasons, or to achieve desiredproperties, for example, to enhance durability, adhesion, or bonding ofprinted material 1210 to curved surface 1202. For purposes of thisdescription, “segments” of printed material 1210 refer to theaccumulation of one or more layers of printed material 1210 forming atleast a portion of a three-dimensional structure. In some embodiments,segments may comprise areas or portions of printed material 1210 thatare smaller than or larger than the segments illustrated in the figuresbelow. In some cases, for example, cleats 1204 may vary in height withrespect to one another and may each comprise a different number oflayers or segments.

In the depiction of FIG. 13, printing is continuing. In FIG. 13, a firstsegment 1300 has been formed along curved surface 1202. First segment1300 is comprised of first layer 1214, where first layer 1214 nowincludes first portion 1212 and an additional second portion 1302. Abottom surface 1306 of first segment 1300 is in contact with curvedsurface 1202, and an upper surface 1304 is associated with the top offirst segment 1300. Thus, in some cases, curved surface 1202 comprisesthe “print surface” 148 described with reference to FIGS. 1-11,providing a printing surface for nozzle 118. In some embodiments,printing of cleats 1204 may include movement of nozzle 118 in agenerally repeating or irregularly round, cyclical, repetitive, orcircular motion to form the structures. In other embodiments, nozzle 118may move in other ways to form, for example, the solid (filled-in)structures, such as second cleat 1208.

In FIG. 14, a first portion 1402 of a second segment 1400 (comprising atleast one printed layer) of printed material 1210 is being depositedonto upper surface 1304 of previously printed first segment 1300. Itshould be noted that second segment 1400 (and any subsequent segments)need not be deposited only on the immediately underlying segment. Indifferent embodiments, variations in printing patterns or thicknesses oflayers are possible. For example, second segment 1400 may be depositedon any desired portion of curved surface 1202, which may include partialor complete coverage of first segment 1300, or may include no coverageof first segment 1300. For example, second segment 1400 may be partiallydeposited on first segment 1300 and partially deposited on the bottomsurface of curved surface 1202. It should also be noted that firstsegment 1300 and second segment 1400 may be joined, attached, bound,coupled, or otherwise connected through one of the techniques describedin the Thread Structure Composition case. For example, in oneembodiment, heat may be applied during the printing process, forming amelted layer of material between upper surface 1304 of first segment1300 and a bottom surface of second segment 1400. The melted layer maybond first segment 1300 (or portions of first layer 1214) to secondsegment 1400.

FIG. 15 illustrates the completion of second segment 1400 printed onfirst segment 1300, forming a first composite segment 1500, includingfirst segment 1300 and second segment 1400 (see FIGS. 13 and 14). Firstcomposite segment 1500 has an upper surface 1502. In FIG. 16, a firstportion 1602 of a third segment 1600 (also comprising at least oneprinted layer) is being formed on upper surface 1502 of first compositesegment 1500. It should be noted that while the printing of cleats 1204is depicted as comprising discrete segments or portions, the formationof a segment may be printed in a continuous manner. For example, firstsegment 1300, second segment 1400, and/or third segment 1600 may beprinted such that there is no discernible distinction between anysegments.

In FIG. 17, a third cleat 1700 has been formed, including first segment1300, second segment 1400, and third segment 1600. Upon completion of athree-dimensional structure along contoured print surface 148, nozzle118 may move in any direction in order to detach printed material 1210from third cleat 1700. For example, in FIG. 17, nozzle 118 has movedupward along the vertical axis and toward forefoot region 210 in adirection aligned with the longitudinal axis, and detached from thirdcleat 1700.

In other embodiments, printing system 100 may be used to form variouspatterns, designs, color forms, and other fabric work along a flat orcurved surface. For example, in some embodiments, printing system 100may be used to print decorative accents that provide an article withpatterns similar to patterns made through embroidery. As is known to onewith ordinary skill in the art, embroidery can be used to decoratefabric or other materials with a needle and thread or yarn. Embroiderymay also incorporate other materials such as metal strips, pearls,beads, quills, and sequins in its patterns. For purposes of thisdescription, the term “embroidered patterns” refers to any type ofdesign, decorative art, fabrication, or other representation added to amaterial. “Embroidered patterns” have been traditionally formed throughstitching or sewing. However, in different embodiments, printing system100 may be used to provide, form, or attach embroidered patterns to acurved surface. Such an application of printing system 100 may allow theformation of embroidered-like designs without the need to pierce thesurface of a fabric or textile, improve the efficiency of embroideredpattern formation, and allow embroidered patterns to be more readilyformed on a variety of objects. In one embodiment, an embroideredpattern may be added to pre-manufactured or pre-fabricatedthree-dimensional articles 130.

For example, in FIGS. 18-19, nozzle 118 is shown as it prints alongmedial side 206 of a fourth article 1800, extruding a printed material1808. In FIG. 18, printing system 100 moves nozzle 118 from a non-zeroprint distance 216 (as described with reference to FIGS. 1-17) intoprint surface 148, such that nozzle 118 directly contacts print surface148, and print distance 216 becomes zero. Thus, as shown in FIG. 18,printing system 100 has moved nozzle 118 from print distance 216 intoprint surface 148, so that nozzle 118 is in direct contact with theattaching surface. In other embodiments, embroidered patterns 1806 maybe formed while maintaining a non-zero print distance 216.

In some embodiments, embroidered patterns 1806 may be formed alongvarious portions of fourth article 1800. For example, a firstembroidered pattern 1802 has been formed along heel region 214 of fourtharticle 1800 along a curved area. In FIG. 19, a series of embroideredpatterns 1806 including second embroidered pattern 1804 have been formedalong forefoot region 210, midfoot region 212, and heel region 214 ofthe three-dimensional contours or curves of fourth article 1800.Printing of embroidered patterns 1806 may involve any of the features ofprinting system 100 described earlier, including first actuating system114 and second actuating system 190.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Although many possible combinations of features are shownin the accompanying figures and discussed in this detailed description,many other combinations of the disclosed features are possible. Anyfeature of any embodiment may be used in combination with or substitutedfor any other feature or element in any other embodiment unlessspecifically restricted. Therefore, it will be understood that any ofthe features shown and/or discussed in the present disclosure may beimplemented together in any suitable combination. Accordingly, theembodiments are not to be restricted except in light of the attachedclaims and their equivalents. Also, various modifications and changesmay be made within the scope of the attached claims.

What is claimed is:
 1. A method of printing on a curved surface of anarticle of apparel, the method comprising: positioning the article ofapparel in a first position on an upper surface of a base of a printingsystem, wherein the upper surface of the base defines a vertical axisthat is perpendicular to the upper surface of the base, and wherein theupper surface of the base defines a first horizontal axis that isparallel to the upper surface of the base and is perpendicular to thevertical axis; discharging a print material from a nozzle of theprinting system; attaching the print material to a print surface of thearticle of apparel, wherein the print surface includes at least onecurved area, by moving the nozzle relative to the article of apparel ina direction aligned with the vertical axis over the print surface andsimultaneously moving the nozzle in a direction aligned with the firsthorizontal axis over the print surface; and attaching the print materialto the print surface by moving the nozzle relative to the article ofapparel in a direction aligned with the vertical axis and simultaneouslymoving the nozzle relative to the article of apparel in a directionaligned with a second horizontal axis, wherein the second horizontalaxis is perpendicular to the first horizontal axis and is parallel withthe upper surface of the base, wherein the nozzle is spaced at a printdistance from the print surface while attaching the print material tothe print surface.
 2. The method according to claim 1, further includingmaintaining a substantially constant print distance between the nozzleand the print surface while printing on the print surface.
 3. The methodaccording to claim 1, wherein the printing system includes an actuatingsystem.
 4. The method according to claim 1, wherein the printing systemincludes a first actuating system configured to move the nozzle relativeto the article of apparel and a second actuating system configured torotate the article of apparel relative to the nozzle.
 5. The methodaccording to claim 1, further including decreasing the print distancebetween the nozzle and the print surface while attaching the printmaterial to the print surface by moving the nozzle downward in adirection aligned with the vertical axis.
 6. The method according toclaim 1, wherein the print material comprises a continuous compositeyarn made of a heat moldable material.
 7. The method according to claim1, wherein the print material comprises a series of droplets.
 8. Themethod according to claim 1, further comprising printing at least onethree-dimensional structure onto the article of apparel.
 9. The methodaccording to claim 1, further comprising forming at least oneembroidered pattern on the article of apparel.
 10. The method accordingto claim 9, wherein the at least one embroidered pattern is formed on anarea of the article of apparel that is curved with respect to thevertical axis.
 11. The method according to claim 1, further comprisingrepositioning the article of apparel using an actuating system such thatthe article of apparel is moved into a second position, wherein thefirst position is different from the second position.
 12. The methodaccording to claim 1, wherein the article of apparel is an undergarment.13. A method of printing on a curved surface of an article of apparel,the method comprising: positioning the article of apparel in a firstposition on an upper surface of a base of a printing system, wherein theupper surface of the base defines a vertical axis that is perpendicularto the upper surface of the base, and wherein the upper surface of thebase defines a first horizontal axis that is parallel to the uppersurface of the base and is perpendicular to the vertical axis;discharging a print material from a nozzle of the printing system;attaching the print material to a print surface of the article ofapparel, wherein the print surface includes at least one curved area, byrepositioning the nozzle relative to the print surface of the article ofapparel in a direction aligned with the vertical axis, in a directionaligned with the first horizontal axis, in a direction aligned with asecond horizontal axis perpendicular to the first horizontal axis, orwith any combination thereof; and simultaneously repositioning thearticle of apparel relative to the print nozzle such that the article ofapparel is moved into a second position, wherein the second position isdifferent from the first position; wherein the nozzle is spaced at aprint distance from the print surface while attaching the print materialto the print surface.
 14. The method according to claim 13, furtherincluding maintaining a substantially constant print distance betweenthe nozzle and the print surface while printing on the print surface.15. The method according to claim 13, wherein the print materialcomprises a continuous composite yarn made of a heat moldable materialor a series of droplets.
 16. The method according to claim 13, whereinthe method further comprises repeating the repositioning of the nozzleand the article of apparel to create a three-dimensional structure. 17.The method according to claim 13, wherein the article of apparel is anundergarment.
 18. The method according to claim 13, wherein the articleof apparel is an athletic support garment.
 19. A method of printing on acurved surface of an undergarment or an athletic support garment themethod comprising: positioning the undergarment or the athletic supportgarment in a first position on an upper surface of a base of a printingsystem, wherein the upper surface of the base defines a vertical axisthat is perpendicular to the upper surface of the base, and wherein theupper surface of the base defines a first horizontal axis that isparallel to the upper surface of the base and is perpendicular to thevertical axis; discharging a print material from a nozzle of theprinting system; attaching the print material to a print surface of theundergarment or the athletic support garment, wherein the print surfaceincludes at least one curved area, by moving the nozzle relative to theundergarment or the athletic support garment in a direction aligned withthe vertical axis over the print surface and simultaneously moving thenozzle in a direction aligned with the first horizontal axis over theprint surface; and attaching the print material to the print surface bymoving the nozzle relative to the undergarment or the athletic supportgarment in a direction aligned with the vertical axis and simultaneouslymoving the nozzle in a direction aligned with a second horizontal axis,wherein the second horizontal axis is perpendicular to the firsthorizontal axis and is parallel with the upper surface of the base,wherein the nozzle is spaced at a print distance from the print surfacewhile attaching the print material to the print surface.